Air-distribution system for a structural unit in a vehicle passenger compartment

ABSTRACT

An air-distribution system ( 20 ) for the distribution of air in a structural unit ( 30 ) in the passenger compartment of a vehicle, in particular in a vehicle seat ( 31 ). The system has at least one air-distribution layer ( 4 ), which is located on a base ( 6 ′), and at least one limiting mechanism ( 41 ′), which at least partially limits the air-distribution layer ( 4 ) laterally at at least one of its peripheral edges ( 53 ). The limiting means ( 41 ′) is designed as at least partially different from base such that it is not integral with the base.

TECHNICAL FIELD

The present invention relates to an air-distribution system for a structural unit in the passage compartment of a vehicle. Such systems are used, for example, in air-conditioned seats, in order to distribute air in the seat surface below a seat cover and then blow it against a passenger.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 5,902,014 discloses air-conditioned seats in which a ventilating layer of a highly porous, air-permeable material is sewn between a seat cushion and a cover. In addition, in DE 19 726 810 a flat heating element is provided between such a ventilation layer and the cover. Such seats are very costly to make, since some of a plurality of layers must be stitched up one after another. In addition, positioning of the ventilation layer on the cushion is very inexact.

EP 1 352 780 discloses a seat in which parts of a cushion of a seat are replaced by inserts of reticulated material. These parts are fed with air. Such parts may slip or require separate fastening elements.

U.S. Publication No. 2005/121965 discloses that insert elements with an adhesive layer may be fastened to projections of a foamed cushion core.

Thus, there exists a need for an improved air distribution system for structural units such as vehicle seats.

SUMMARY OF THE INVENTION

The present invention provides an air-distribution system which is easy to assemble, simply manageable logistically and reliable in operation, and requires as little as possible modification of a structural part to be ventilated.

In one embodiment, the present invention provides an air-distribution system for a structural unit in a passenger compartment of a vehicle, such as a vehicle seat, having at least one air-distribution layer which is located on a base, and at least one limiting mechanism, which at least partially limits the air-distribution layer laterally at at least one of its peripheral edges. The limiting mechanism is at least partially designed as different from the base. It is not integral with the base. In one aspect of the invention, the limiting mechanism can be placed at least indirectly on the air-distribution layer, such as on an accompanying layer located at least partially approximately parallel to the air-distribution layer. This can be accomplished by an adhesive and/or by threading. The air-distribution layer can be placed between a cover and a cushion, which can serve as the base.

The base can be provided with a variety of zones, which are delimited from one another by depressions, elevations or varying height levels. Further, at least one zone can be delimited by the limiting mechanism or an additional limiting mechanism from at least one additional zone.

The accompanying layer can include at least two sections of the air-distribution layer at least partially separated and at a distance from each other. These can be located in the same plane with one another and along the accompanying layer between which is located at least one limiting mechanism which can be fastened to the accompanying layer. In another aspect, an electrical conductor such as a linear conductor in the form of a cable or heating conductor, runs from a first section to a second section of the air-distribution layer. It can be routed such that it turns and twists or meanders about its main direction of run, i.e., it is not along the shortest possible route.

The invention is advantageous in that the limiting mechanism serves to form a clear edge shape, e.g., owing to a more suitable material than that of the air-distribution layer. However, it may alternatively serve for lateral sealing of the air-distribution layer, in order to prevent air losses.

Other advantages will become apparent with reference to the following detailed description, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is described below by way of examples with reference to a number of embodiments and their drawings, wherein:

FIG. 1 shows a cross section through a cushion of a vehicle seat incorporating an embodiment of the present invention.

FIG. 2 shows a longitudinal section through the cushion of the vehicle seat of FIG. 1.

FIG. 3 shows a perspective view of a seat with an additional embodiment of an air-distribution system partially open.

FIG. 4 shows a view from below of an air-distribution system of FIG. 1.

FIG. 5 shows a cross section through a first embodiment of a limiting mechanism.

FIG. 6 shows a cross section through a second embodiment of a limiting mechanism of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

In the following figures, the same reference numerals are used to refer to the same components. While the present invention is described as an air conditioning system for use within a vehicle seat, it may be adapted and applied to various systems including other vehicle or non-vehicle systems requiring an air conditioned surface. In this regard, in the following description, various operating parameters and components are described for several constructed embodiments. These specific parameters and components are included as examples only and are not meant to be limiting.

In FIGS. 1 and 2, a cushion 6 is provided in a structural unit 30 in the passenger compartment, in the example a seat 31. This cushion has a recess 35 at its side turned toward the passenger. This recess 35 is limited transverse to the direction of travel F by cushion elevations 41 and foam strips as cushion boundaries 41′ along the direction of travel F. Depressions 7 are provided on the sides of the cushion elevations 41/cushion boundaries 41′ turned away from the recess 35. The recess 35 and the cushion elevations 41 are provided in a first cushion zone 6 a.

A second cushion zone 6 b is also provided, which with regard to a recess 35′, cushion elevations 41/cushion boundaries 41′ and depressions 7 is designed similar to the first cushion zone. However, depending upon the application under consideration, the area of the second recess 35′ can be different from that of the first recess 35.

An air-distribution system 20 is placed on the cushion 6. The air-distribution system 20 has an air-distribution layer 4. This is made, for example, of a knitted spacer fabric (as here), rubberized hair, foam, of a multiplicity of coils placed alongside one another or of some other material through which air is able to flow.

In the present exemplary embodiment, the air-distribution layer 4 has two sections 43, 43′ separated from one another and at some distance apart. These correspond in their area to approximately the area of the recesses 35, 35′. The thickness of the sections 43, 43′ corresponds to approximately the depth of the recesses 35, 35′. The sections 43, 43′ are located so that they are accommodated in the recesses 35, 35′. The two sections 43, 43′ are, in the present example, made of like material and are similarly designed. However, they may, for example for the optimization of cushion hardness or ability to withstand load, have dissimilar elasticity or unlike materials or material thicknesses.

An accompanying layer 2 a is placed on the air-distribution layer 4. It is located on the side of the air-distribution layer 4 turned away from the cushion 6. The accompanying layer 2 a projects at least partially beyond the area of the air-distribution layer 4. An adhesive surface 5 is provided at the projecting overhang 25. In the exemplary embodiment shown, the adhesive layer 5 runs around the sections 43, 43′ of the air-distribution layer 4. It is advantageously formed by a band of self-sealing film.

Further fastening can be provided by embedding one component of a hook-and-loop fastener in the cushion and providing the corresponding component on the adhesive surface of the air-distribution system or making the air-distribution layer and/or the accompanying layer of a textile hook-and-loop material. Instead of cementing, a hook-and-loop fastening is then produced.

The accompanying layer 2 a may be made exclusively of the adhesive surface 5. In the present example, however, it has a layer 3 of cushion material. In addition, a flat heating element 2 b is placed on the accompanying layer 2 a. The cushion layer 3 and the heating element 2 b may be cemented, stitched, knit or woven together.

The sections 43, 43′ and the accompanying layer 2 a are placed together in such a way that the sections 43, 43′ in the cushion zones 6 a, 6 b are covered all over, and that the accompanying layer 2 a reaches all the way to the bottom of the depression 7 between the two cushion zones 6 a, 6 b. In the present case, this depression 7 is an anchoring furrow. The adhesive layer 5 adheres to the elevations 41. As a result, a smooth transition between the elevations 41 and the air-distribution layer 4 is ensured and the air-distribution layer 4 is firmly and immovably fixed. The limiting mechanism 41′ can be first placed on the accompanying layer 2 a and then, when the accompanying layer 2 a is put in place on the cushion 6, it can be joined, preferably cemented, to the accompanying layer.

The air-distribution system 20 has in particular in the air-distribution layer 4 a low resistance to air flowing along the air-distribution layer than transverse to the air-distribution layer. In addition, it has high vapor permeability and/or air permeability perpendicular to the air-distribution layer 4. The air-distribution system 20 is covered by a cover 1. The cover 1 may be cemented to the cushion 6 and the air-distribution system 20. In the present example, it is sewn on and/or anchored along the depression 7.

FIG. 3 shows, in an additional exemplary embodiment, a seat 31, a cushion 6 with two recesses 35, 35′ and an air-distribution system 20. They correspond substantially to the first exemplary embodiment, although without anchoring furrows. Rather, the two recesses 35, 35′ are connected together, in an air permeable way through a passage 55.

In the recess 35′, a channel 47 is provided which accommodates an electrical connecting cable 9 of the air-distribution system 20. The channel 47 extends from the bottom of the recess 35 through the cushion 6 and again emerges from the cushion 6 at a suitable place, e.g., at the back or front.

In the recess 35 there is in addition provided an opening 49. The latter serves for the passage of air and connects the air-distribution layer 4 with the surroundings of the seat 31. It therefore advantageously runs as directly as possible and in a straight line to the side of the cushion 6 turned away from the air-distribution system 20.

A blower or fan 8 is provided in the opening 49. The blower 8 serves to supply air to or suction it away from the air-distribution system 20.

It can readily be seen that the air-distribution layer 4, the adhesive surface 5 and the additional functional elements such as the electric heating element 2 b form a coherent, easy-to-handle assembly. Additional limiting mechanisms could alternatively be mounted on it. This assembly can easily be set form-lockingly into the recess 35 and permanently fastened thereto.

The air-distribution system 20 may alternatively have a moist buffering layer, for example a non-woven fabric with activated carbon particles, for example as part of the accompanying layer 2 a. In addition, the air-distribution system may be equipped with sensors, blowers or additional functional elements. Cushion-stiffening elements or multiple-zone foams may alternatively be placed thereon. Molded parts of rubberized hair are especially suitable for the seat surface region.

FIG. 4 shows an embodiment of an air-distribution system 20 that corresponds to the first embodiment of FIG. 1. In the top view can be seen electrical conductors 11, which run from the first section 43 of the air-distribution layer 4 to the second section 43′. These electrical conductors 11 are fixed to the accompanying layer 2 a. They do not run in a straight line, nor on the shortest path from one section to the other. Rather, their main direction of run is turning and twisting to the shortest possible connection and they meander about this main direction of run. In this way, the conductors 11 get sufficient free space for movement in order to bridge anchoring furrows or other depressions 7 and seams, without being damaged by overextension or fracture in case of load.

FIGS. 5 and 6 show a part of the vehicle seat in cross-section through the seat part. The base 6′ is represented in the form of the cushion 6. This has a central seat zone 6 a. Here an air-distribution layer 4 is placed on the base 6′. The air-distribution layer 4 has a multiplicity of coils 51 arranged approximately parallel to one another, between which air is able to flow. The coils 51 preferably are placed material-lockingly on the accompanying layer 2 a and fastened thereto.

The accompanying layer 2 a is located on the side of the air-distribution layer 4 lying opposite the base 6′. An air-permeable heating element 2 b is arranged over the accompanying layer 2 a with a number of heating conductors which can be seen here in cross section.

The air-distribution layer 4 is delimited laterally by a limiting mechanism 41′. This can have an elongated structural element made of foam material. It can be placed at least partially along the accompanying layer 2 a and surrounded at least partially by the accompanying layer 2 a. For example, it can be driven into the accompanying layer 2 a. However, it may alternatively simply be placed on it, as in FIG. 6. It may also be stitched or cemented to it.

In order to increase the sturdiness and accuracy of fit of the inserted assembly, it may be advantageous to provide a deepened zone 6 b especially for accommodation of the limiting mechanism 41′. However, it is not absolutely necessary, as can also be seen in FIG. 6. The limiting mechanism 41′ serves, among other things, to delimit the zone 6 d of the seat side pieces and the zones 6 a, 6 b, which are separated from each other by a furrow at the zone 6 c, sharp-edged from each other. For fastening the assembly made up of the air-distribution layer 4, the accompanying layer 2 a, the heating element 2 b and the limiting mechanism 41′, an adhesive layer 5, for example an adhesive tape or a hook-and-loop fastener, is advantageous. For example, a part 5′, such as a half or component of a hook-and-loop fastener, is material-lockingly joined with the base 6′, for example embedded in the foam of the cushion 6.

Multiple variants of the invention are possible. The invention is not limited to seats. It may also be provided in adapted form for example for armrests, door panels and instrument panels. As limiting mechanisms, instead of a strip of foam material, any medium can be used that reduces, or substantially prevents passage of air at least at parts of at least one peripheral edge of the air-distribution layer to the sides of the seat and/or to the air-distribution layer.

In order to form the limiting mechanism of the base differently and not in one piece with it, any embodiment is suitable in which the limiting mechanism and the base, before they are joined, are structures at least partially spaced apart from each other, at least temporarily. For example, projecting parts of a cushion could alternatively be at least partially cut off, joined with the air-distribution layer and then be cemented again with the cushion at their original position.

Alternatively to a boundary at the side pieces, a peripheral edge may alternatively be understood to be any other desired section of the edge path of the air-distribution layer or one of its sections. It is advantageous when the non-integral limiting mechanism is combined with projections produced integral with the cushion. It is also advantageous when only one such projection, preferably designed elongated, is otherwise combined with non-integral limiting mechanism for the limitation of all sides of the air-distribution layer.

By “limiting” is to be understood not only that the limiting mechanism is placed alongside the air-distribution layer. It may in addition alternatively be placed partially or completely at a distance from the air-distribution layer. What is significant is that it be located at least partially between the ventilation layer and the outer side contours of the seat and/or the structural unit and lie at least partially in the plane determined by the air-distribution layer (not absolutely flat).

While the invention has been described in connection with one or more embodiments, it is to be understood that the specific mechanisms and techniques which have been described are merely illustrative of the principles of the invention, numerous modifications may be made to the apparatus described without departing from the spirit and scope of the invention as defined by the appended claims. 

1. An air-distribution system for a structural unit comprising at least one air-distribution layer located on a base, and at least one limiting mechanism which at least partially limits the air-distribution layer laterally at at least one of its peripheral edges wherein the limiting mechanism, at least partially, is not integral with the base.
 2. An air-distribution system according to claim 1, wherein the limiting mechanism is placed at least indirectly on the air-distribution layer, by way of an accompanying layer located at least partially approximately parallel to the air-distribution layer.
 3. An air-distribution system according to claim 2 wherein the limiting mechanism is secured to the air-distribution layer by an adhesive or threading.
 4. An air-distribution system according to claim 1, wherein the air-distribution layer is placed between a cover and a cushion which serves as the base.
 5. An air-distribution system according to claim 2, wherein the air-distribution layer is placed between a cover and a cushion which serves as the base.
 6. An air-distribution system according to claim 1, wherein the base comprises a plurality of zones, which are delimited from one another by depressions, elevations or changes in height, and wherein at least one zone is delimited by the limiting mechanism or an additional limiting mechanism from at least one other zone.
 7. An air-distribution system according to claim 2, wherein the base comprises a plurality of zones, which are delimited from one another by depressions, elevations or changes in height, and wherein at least one zone is delimited by the limiting mechanism or an additional limiting mechanism from at least one other zone.
 8. An air-distribution system according to claim 4, wherein the base comprises a plurality of zones, which are delimited from one another by depressions, elevations or changes in height, and wherein at least one zone is delimited by the limiting mechanism or an additional limiting mechanism from at least one other zone.
 9. An air-distribution system according to claim 2, wherein at the accompanying layer there are located at least two sections of the air-distribution layer at least partially separated and at a distance from each other, the sections being substantially in the same plane to one another and along the accompanying layer, and wherein at least one limiting mechanism is located between two adjacent sections.
 10. An air-distribution system according to claim 5, wherein at the accompanying layer there are located at least two sections of the air-distribution layer at least partially separated and at a distance from each other, the sections being in the same plane to one another and along the accompanying layer, and wherein at least one limiting mechanism is located between two adjacent sections.
 11. An air-distribution system according to claim 7, wherein at the accompanying layer there are located at least two sections of the air-distribution layer at least partially separated and at a distance from each other, the sections being in the same plane to one another and along the accompanying layer, and wherein at least one limiting mechanism is located between two adjacent sections.
 12. An air-distribution system according to claim 9 wherein the sections are fastened to the accompanying layer.
 13. An air-distribution system according to claim 9 comprising at least one electrical conductor running from a first section to a second section of the air-distribution layer, the conductor being arranged in a non-straight route about its primary direction of run.
 14. An air-distribution system according to claim 10 comprising at least one electrical conductor running from a first section to a second section of the air-distribution layer, the conductor being arranged in a non-straight route about its primary direction of run.
 15. An air-distribution system according to claim 11 comprising at least one electrical conductor running from a first section to a second section of the air-distribution layer, the conductor being arranged in a non-straight route about its primary direction of run.
 16. An air-distribution system according to claim 13 wherein said electrical conductor comprises a linear cable or heating conductor.
 17. An air-distribution system according to claim 1 comprising an adhesive surface on at least half of an edge length of the area of the air-distribution layer, the adhesive surface being a self-sealing or hook-and-loop surface, in order to fasten the air-distribution system to the base.
 18. An air-distribution system according to claim 2, wherein the accompanying layer is substantially formed by an adhesive surface.
 19. An air-distribution system according to claim 2, wherein the accompanying layer comprises layers of cushion material which substantially cover the air-distribution layer.
 20. An air-distribution system according to claim 1, comprising a flat heating element is located on the air-distribution layer.
 21. An air-distribution system according to claim 2, comprising a flat heating element is located on or in the accompanying layer. 